Vehicle seat assembly having layered seating system

ABSTRACT

A vehicle seat cushion composite is provided with a structural layer adapted to be mounted within a vehicle to provide support to an occupant. The structural layer has at least two edge regions provided proximate two edges of the structural layer and an inner region at least partially bound within the at least two edge regions. The at least two edge regions have a plurality of concave channels. A cushion layer is adjacent to the structural layer and has a plurality of concave projections sized to be received within the plurality of concave channels of the structural layer for minimizing lateral movement of the cushion layer relative to the structural layer proximate the edge regions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.12/357,084 filed Jan. 2, 2009, the disclosure of which is incorporatedin its entirety by reference herein.

TECHNICAL FIELD

Multiple embodiments relate to a vehicle seat assembly having a layeredseating system.

BACKGROUND

Most seat assemblies include three fundamental components: (a) a frameto support the seat assembly and mount it to a body, such as a vehicle;(b) a foam cushion to cover the frame; and (c) trim material to coverthe foam cushion and provide a durable surface for contact with a seatassembly occupant. A conventional vehicle seat design typically involvesthe mixing of base construction polymers joined in a manner that isdifficult to disassemble and not focused on environmentally friendlymaterial use.

Accordingly, there is a need for a vehicle seat assembly which isenvironmentally friendly, structurally sound and comfortable, andrelatively easy to assemble and disassemble as needed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cut-away environmental view of an embodiment of avehicle seat assembly;

FIG. 2 is a cross-sectional view of a portion of an embodiment of thevehicle seat assembly of FIG. 1;

FIG. 3 is a top plan view of a portion of the vehicle seat assembly ofFIG. 2;

FIG. 4 is cross-sectional view of a portion of another embodiment of thevehicle seat assembly of FIG. 1;

FIG. 5 is a top plan view of a portion of the vehicle seat assembly ofFIG. 4;

FIG. 6 is a cross-sectional view of a portion of another embodiment ofthe vehicle seat assembly of FIG. 1;

FIG. 7 is a top plan view of a portion of the vehicle seat assembly ofFIG. 6;

FIG. 8 a is a cross-sectional view of yet another embodiment of aportion of the vehicle seat assembly of FIG. 1;

FIG. 8 b is another cross-sectional view of a portion of the vehicleseat assembly of FIG. 8 a;

FIG. 9 is a top plan view of a portion of the vehicle seat assembly ofFIGS. 8 a-8 b;

FIG. 10 is a front perspective view of an embodiment of a portion of thevehicle seat assembly of FIG. 1;

FIG. 11 is a cross-sectional view of a portion of the vehicle seatassembly of FIG. 10 taken along the line 11-11;

FIG. 12 is a cross-sectional view of a portion of the vehicle seatassembly of FIG. 10 taken along the line 12-12;

FIG. 13 is a cross-sectional view of a portion of the vehicle seatassembly of FIG. 10 taken along the line 13-13; and

FIG. 14 is a cross-sectional view of a portion of the vehicle seatassembly of FIG. 10 taken along the line 14-14.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for the claims and/or as a representative basis forteaching one skilled in the art to variously employ the presentinvention.

Moreover, except where otherwise expressly indicated, all numericalquantities in the description are to be enlisted as modified by the word“about” in describing the broader scope of the invention. Practicewithin the numerical limit stated is generally preferred. Also, unlessexpressly stated to the contrary, the description of a group or class ofmaterials is suitable or preferred for a given purpose in connectionwith the invention implies that mixtures of any two or more members ofthis group or class may be equally suitable or preferred.

Referring to FIG. 1, a vehicle seat assembly 10 is illustrated. Whilethe vehicle seat assembly 10 is illustrated in FIG. 1 to be a bucketseat assembly, it should be understood that the principles of theinvention are applicable to other types of seat assemblies, such asbench, captain and other types of seat assemblies. It should also beunderstood that the principles of the present invention are applicableto other configurations where foam is a component, such as backrests,back support pads, armrests, and head restraints. Still further, itshould be understood that the principles of this invention areapplicable to all types of vehicle seat assemblies. Furthermore, itshould be understood that the teachings of the multiple embodiments arenot limited to applications on automobiles but may be employed on anytype of vehicle including, without limitation, aircraft, watercraft,spacecraft, and other types of landcraft including trains as well asnon-vehicle seat assemblies.

As shown in FIG. 1, the vehicle seat assembly 10 includes a seat frame,generally indicated at 12 having a plurality of mounting bracketsadapted to operatively secure the seat frame 12 within a vehicle. Theseat frame 12 may be constructed from any materials suitable forapplication within a vehicle seat assembly 10, such as aluminum, steelor other metal alloy, composite material, or a suitable polymer.Further, the seat frame 12 may be manufactured using techniques commonlyknown in the art, and relative to the type of material employed. By wayof example, the manufacturing techniques may include stamping, welding,fastening or molding a suitable material to form the seat frame 12.

The vehicle seat assembly 10 also includes a seat back, generallyindicated at 14 and a lower seat assembly, generally indicated at 16. Inat least the illustrated embodiment, the seat back 14 and the lower seatassembly 16 each have the same cushion composite 18 covered by a trimmaterial 20. However, it should be understood that the configuration ofthe cushion composite 18 for the seat back 14 can differ from theconfiguration of the cushion composite 18 of the lower seat assembly 16.Likewise, it should be understood that the trim material 20 for the seatback 14 can differ from the trim material for the lower seat assembly16. The cushion composite 18 includes a structural layer 22, in at leastthe illustrated embodiments, disposed over frame 12 and a cushion layer24 that is disposed over the structural layer 22. The cushion composite18 could include other optional layers such as a comfort pad. As will beexplained further below, each of the layers cooperate with and in someembodiments are secured to each other in a manner such that they arerelatively easily separable for recycling at end of use.

The structural layer 22 can be any suitable structural foam material. Inat least one embodiment, suitable structural materials will have arigidity and/or density that is higher than conventional polyurethanefoam. In at least one embodiment, suitable structural foam materialshave a density of at least 1.75 pounds per cubic foot (pcf), and lessthan 7.0 pcf. In at least another embodiment, the suitable structuralfoam materials will have a density of 2.0 to 4.0 pcf, and in yet otherembodiments of 2.5 to 3.5 pcf. Density of the structural foam materialcan be measured in accordance with ASTM test method No. D3574.

In at least one embodiment, suitable structural materials will have ahardness of 150 to 250 Newtons (N), in at least another embodiment of175 to 230 N, and in at least another embodiment of 190 to 215 N.Hardness can be measured by ASTM test method No. D3574 and at 25%compression or deflection. In at least one embodiment, suitablestructural materials will have a compression strength of 20 to 100pounds per square inch (psi), in at least another embodiment of 30 to 80psi, and in at least another embodiment of 35 to 65 psi, as measured inaccordance with ASTM test method No. D3574.

In at least one embodiment, the structural layer 22 comprises a moldedexpanded polyolefin (EPO) layer. Suitable examples of expandedpolyolefin (EPO) include, but are not necessarily limited to, expandedpolyethylene (EPE), expanded polypropylene (EPP), expanded polybutylene(EPB), and copolymers of ethylene, propylene, butylene, 1,3-butadiene,and other olefin monomers, such as alpha-olefin monomers having from5-18 carbon atoms, and/or cycloalkylene monomers such as cyclohexane,cyclopentene, cyclohexadiene, norbornene, and aromatic substitutedolefins, such as styrene, alpha-methylstyrene, paramethylstyrene, andthe like.

In at least one particular preferred embodiment, the EPO is expandedpolypropylene (EPP) and its copolymers with ethylene, propylene andbutylene. Any suitable EPP may be used, however in at least oneembodiment, suitable EPP's include, but are not limited to, ARPRO® EPPavailable from JSP International and EPP available from Createch LTD.

Expanded polyolefins can be prepared by a bead polymerization process inwhich relatively small uniform beads of polymer are produced, containinga gas which is later utilized to effect blowing during the moldingprocess. The most commonly used gas is air although other gasesincluding low boiling point liquids which produce gases at the moldingtemperatures may be used. Suitable gases include, but are not limited toair, nitrogen, carbon dioxide, pentene and the like.

While the structural layer 22 can have any suitable size andconfiguration, in at least one embodiment, the structural layer 22 hasan average thickness of five to one hundred millimeters, in otherembodiments of twenty to seventy millimeters, and in yet otherembodiments of thirty to fifty millimeters. The structural layer 22 maybe a seat body that is adapted to be mounted within the vehicle.

The cushion layer 24 can comprise any suitable cushion material, such asa suitable resilient polymer. In at least one embodiment, suitablecushion materials will have a density of 1.5 to 4.5 pcf, in anotherembodiment of 2.0 to 3.75 pcf, and in yet other embodiments of 2.7 to3.0 pcf. Density of the cushion material can be measured by ASTM testmethod No. D3574. In at least one embodiment, suitable cushion materialswill have a hardness of 175 to 400 N, in other embodiments of 225 to 350N, and in yet other embodiments of 275 to 325 N. Hardness of the cushionmaterial can be measured by ASTM test method No. D3574. In at least oneembodiment, suitable cushion materials will have a hysteresis of 18 to30 kilopascals (KPa), in another embodiments of 20 to 28 KPa, and in yetother embodiments of 23-26 KPa. Hysteresis of the cushion material canbe measured by ASTM test method No. D3574.

In at least certain embodiments, the cushion material comprisesconventional polyurethane foam, soy-based foam, silicone, thermoplasticolefins, thermoplastic urethanes, and/or natural oil-based expandedpolyurethanes and the like. In at least one embodiment, because of itsenvironmentally friendly nature, soy-based polyurethane is preferred.Soy-based polyurethane can be made with any suitable soy-based polyols,such as those available, but not necessarily limited to, from Bayer,Urethane Soy Systems, and Dow Chemical. Any suitable soy-basedpolyurethane may be used, however in at least one embodiment, suitablesoy-based polyurethanes include, but are not necessarily limited tothose available from Woodbridge Foam. The cushion layer 24 can be anysuitable size and shape, however, in at least one embodiment, thecushion layer 24 has an average thickness of twenty to one hundredmillimeters, and in at least another embodiment of thirty to seventymillimeters, and in still yet other embodiments of forty to sixtymillimeters. The cushion layer 24 may be a seat component that isprovided adjacent to the seat body, which may be the structural layer22.

As discussed, the vehicle seat assembly 10 also includes trim material20 which is adapted to engage the cushion composite 18 in a coveringrelationship. The trim material 20 may include any material known in theart. By way of example, some of the known materials include cloth,leather or polymers of sufficient quality and thickness for use in seattrim applications. Polymer trim materials may include a flexible closecell polymer skin material such as polyvinyl, polyvinyl chloride (PVC),polyester, nylon, thermoplastic olefin (TPO) or thermoplastic urethane(TPU). Additional materials for use as trim material 20, may include afoam backing (not shown, but generally known in the art) which may bemanufactured from a variety of polymer foam materials. By way ofexample, the foam backing may be polyethylene, polypropylene,polyurethane, or a polystyrene foam. Optionally, a mesh or reinforcingmaterial (generally known in the art) such as fiberglass, nylon,polyester or natural fibers may be applied to the foam backing or backof the trim material 20 for increase in strength without increasingrigidity. In at least one particularly preferred embodiment, the trimmaterial 20 comprises polyester or nylon trim material having polyesteror nylon trim fasteners for securing the trim material 20 to one or morecomponents (i.e., cushion 18 and/or frame 12) of the vehicle seatassembly 10.

When the cushion layer 24 is mounted to the structural layer 22, thecushion layer 24 can move laterally relative to the structural layer 22.Often adhesives velcro, and/or other bonding materials are employed tomount the cushion layer 24 to the structural layer 22 in order to reducelateral movement of the cushion layer 24. Utilization of adhesivesvelcro, and/or other bonding materials requires additional material tobe added to the cushion composite 18, which increases manufacturingcosts by requiring additional material and requiring additionalmanufacturing time.

With reference now to FIG. 2, a cross-sectional view of an embodiment ofthe cushion composite 18 is illustrated covered by trim material 20. Asillustrated, the structural layer 22 of the cushion composite 18 hasedges 26. Edge regions 28 are provided proximate the edges 26 of thestructural layer 22. Between the edge regions 28 in an inner region 30.As illustrated, the inner region 30 is bound on four sides by the edgeregions 28. The edge regions 28 may each have widths of five to tencentimeters in one embodiment. In another embodiment, the edge regions28 may have widths of ten to twenty centimeters. The edge regions 28 mayhave similar or varying widths.

The edge regions 28 of the structural layer 22 have a plurality ofchannels 32 formed therein. In the illustrated embodiment, threechannels 32 are formed in each edge region 28. Of course, any suitableamount of channels 32 is contemplated within the scope of the disclosedembodiments.

The channels 32 in the edge regions 28 receive protrusions 34 thatextend from the cushion layer 24. During assembly of the cushioncomposite 18, the protrusions 34 on the cushion layer 24 facilitateproper installation of the cushion layer 24 relative to the structurallayer 22 because the protrusions 34 fit into the channels 32 within thestructural layer 22. An interference fit may be employed between thechannels 32 and the protrusions 34 to retain the protrusions 34 withinthe channels 32. Of course, the protrusions 34 may be retained withinthe channels 32 in any suitable manner.

When the cushion composite 18 is in use to support an occupant, theprotrusions 34 facilitate alignment of the cushion layer 24 relative tothe structural layer 22 and minimize lateral movement of the cushionlayer 24 relative to the structural layer 22. Minimization of lateralmovement of the cushion layer 24 is important for the cushion composite18 in order to keep the cushion composite 18 together and comfortablefor the occupant. Additionally, locating the channels 32 in the edgeregions 28 of the structural layer provides vital retention duringoccupant ingress and egress as the occupant provides lateral movement ofthe cushion layer 24 relative to the structural layer 22.

In addition to channels 32 provided in the edge regions 28 of thestructural layer 22, channels 36 may be provided within the inner region30 that is provided between the edge regions 28. Although three channels36 are illustrated in the inner region 30, any suitable amount ofchannels 36 is contemplated within the scope of the disclosedembodiments.

The channels 36 in the inner region 30 each receive a protrusion 38 thatextends from the cushion layer 24. During assembly of the cushioncomposite 18, the protrusions 38 on the cushion layer 24 facilitateproper installation of the cushion layer 24 relative to the structurallayer 22 because the protrusions 38 fit into the channels 36 within thestructural layer 22. An interference fit may be employed between thechannels 36 and the protrusions 38 to retain the protrusions 38 withinthe channels 36. Of course, the protrusions 38 may be retained withinthe channels 36 in any suitable manner.

When the cushion composite 18 is in use to support an occupant, theprotrusions 36 may further facilitate alignment of the cushion layer 24relative to the structural layer 22 and minimize lateral movement of thecushion layer 24 relative to the structural layer 22. Minimization oflateral movement of the cushion layer 24 is important for the cushioncomposite 18 in order to keep the cushion composite 18 together andcomfortable for the occupant. Lateral movement may occur during occupantingress or egress, during normal riding conditions when the occupant issitting upon the cushion composite 18 or during an impact condition whenthe vehicle is impacted against another object.

When the channels 32 of the edge region 28 of the structural layer 22and protrusions 34 of the cushion layer 24 and the channels 36 of theinner region 30 of the structural layer 22 and protrusions 38 of thecushion layer 24 are employed, the cushion composite 18 can be securedto the structural layer 22 without the use of adhesives velcro, and/orother bonding materials.

The channels 32, 36 may have various, similar and/or equal depths whilethe protrusions 34, 38 have corresponding lengths. As illustrated, thechannels 32 may have increased depths proximate to the edge 26 of thestructural layer 22 to facilitate retention of the cushion layer 24 onthe structural layer 22 during occupant ingress and egress, duringnormal riding conditions and during impact conditions. In oneembodiment, at least one of the channels 32, 36 has a depth ofapproximately five to twenty-five millimeters. A depth of approximatelyfive to twenty-five millimeters facilitates retention of a similarlysized protrusion 34, 38 within the channel 32, 36. In one embodiment, atleast one of the channels 32, 36 has a depth of approximately tenmillimeters. In another embodiment, at least one of the channels 32, 36has a depth of approximately fifteen millimeters. In yet anotherembodiment, at least one of the channels 32, 36 has a depth ofapproximately twenty millimeters. A larger depth may be felt by theoccupant when sitting upon the cushion composite 18, which may decreasecomfort for the occupant. Of course, any suitable depth for the channels32, 36 is contemplated within the scope of the multiple disclosedembodiments.

The channels 32, 36 may also have various, similar and/or equal widthswhile the protrusions 34, 38 have corresponding widths to fit within thechannels 32, 36. In one embodiment, at least one of the channels 32, 36has a width of approximately five to thirty millimeters. A width of fiveto thirty millimeters facilitates retention of a similarly sizedprotrusion 34, 38 within the channel 32, 36. In one embodiment, at leastone of the channels 32, 36 has a width of approximately fifteenmillimeters. In another embodiment, at least one of the channels 32, 36has a width of approximately twenty millimeters. In yet anotherembodiment, at least one of the channels 32, 36 has a width ofapproximately thirty millimeters. Of course, any suitable width for thechannels 32, 36 is contemplated within the scope of the multipledisclosed embodiments.

In FIG. 3, the channels 32 provided in the edge regions 28 of thestructural layer 22 and the channels 36 provided within the inner region30 of the structural layer 22 are illustrated. In the depictedembodiment, the channels 32 formed in the edge regions 28 have a concaveprofile relative to the edge 28 of the structural member 22, as depictedin the top plan view. The concave channels 32 facilitate retention ofthe cushion layer 24, as depicted in FIG. 2, because during occupantingress and egress, the protrusions 34 remain locked within the concavechannels 32, which may have an interference fit provided therebetween.The concave channels 32 may have an arcuate shape, as illustrated in thetop plan view, or may have an arrow concave shape. Of course, anysuitable concave shape for the channels 32 when viewed from the top planview is contemplated within the scope of the disclosed embodiments.

In the illustrated embodiment, multiple concave channels 32 are formedwithin the structural layer 22. Providing multiple concave channels 32may increase retention of the protrusions 34 within the concave channels32. Additionally, the concave channels 32 may be provided at multiplelocations of the edge region 28 of the structural layer 22. The cushionlayer 24 shown in FIG. 2 may have corresponding protrusions 34 that aresized to be received within the concave channels 32.

In at least the depicted embodiment of FIG. 3, the channels 36 providedwithin the inner region 30 the structural layer 22 have a concaveprofile relative to the edge 28 of the structural member 22. The concavechannels 36 retain the protrusions 28 of the cushion layer 24 shown inFIG. 2 when the occupant is resting upon the cushion composite 20 duringnormal riding conditions or during impact conditions. The concavechannels 36 may have an arcuate shape or may have an arrow concave shapeillustrated. Of course, any suitable concave channel shape iscontemplated for the channels 36 provided within the inner region 30 ofthe structural layer 22.

With reference now to FIG. 4, a cross-sectional view of anotherembodiment of the cushion composite 18 is illustrated with the supportlayer 22 supporting the cushion layer 24 and covered by trim material20. In the depicted embodiment, a recess 40 is provided proximate eachedge 26 in each edge region 28 of the structural layer 22. The cushionlayer 24 has corresponding protrusions 42 that are sized to be receivedwithin the recesses 40 of the structural layer 22. The protrusions 42facilitate locating the cushion layer 24 on to the structural layer 22during assembly and retain the cushion layer 24 on the structural layer22 during occupant ingress and egress. An interference fit may beemployed between the recesses 40 and the protrusions 42 to retain theprotrusions 42 within the recesses 40. Of course, the protrusions 42 maybe retained within the recesses 40 in any suitable manner.

The recesses 40 may have various, similar and/or equal depths while theprotrusions 42 have corresponding lengths. In one embodiment, at leastone of the recesses 40 has a depth of approximately five to twenty-fivemillimeters. A depth of five to twenty-five millimeters facilitatesretention of a similarly sized protrusion 42 within the recesses 40. Inone embodiment, at least one of the recesses 40 has a depth ofapproximately ten millimeters. In another embodiment, at least one ofthe recesses 40 has a depth of approximately fifteen millimeters. In yetanother embodiment, at least one of the recesses 40 has a depth ofapproximately twenty millimeters. A larger depth for the recesses 40 maybe felt by the occupant when sitting upon the cushion composite 18,which may decrease comfort for the occupant. As illustrated, the recess40 may extend through a portion of the structural layer 22. In at leastanother embodiment, illustrated in FIGS. 6-8 a, the recesses 40 areformed through the structural layer 22 and the protrusions 42 extendthrough the structural layer 22. Of course, any suitable depth for therecesses 40 is contemplated within the scope of the multiple disclosedembodiments.

The recesses 40 may also have various, similar and/or equal widths whilethe protrusions 42 have corresponding widths to fit within the recesses40. In one embodiment, at least one of the recesses 40 has a width ofapproximately five to thirty millimeters. A width of five to thirtymillimeters facilitates retention of a similarly sized protrusion 42within the recesses 40. In one embodiment, at least one of the recesses40 have a width of approximately fifteen millimeters. In anotherembodiment, at least one of the recesses 40 has a width of approximatelytwenty millimeters. In yet another embodiment, at least one of therecesses 40 has a width of approximately thirty millimeters. Of course,any suitable width for the recesses 40 is contemplated within the scopeof the multiple disclosed embodiments.

The inner region 30 of the structural layer 22, as illustrated in FIGS.4-6, may have channels 36 formed therein, as discussed above withreference to FIG. 2. Additionally, the cushion layer 24 may havecorresponding protrusions 38 extending therefrom to be retained withinthe channels 36 of the structural layer 22, as discussed above withreference to FIG. 2.

In FIG. 5, an embodiment with the recesses 40 formed in variouslocations on the structural layer 22 is illustrated. The recesses 40 maybe formed the edge region 28 proximate the edge 26 of the structurallayer 22 and may be formed in the inner region 30. In at least oneembodiment, the recesses 40 are only formed in the edge region 30. Ofcourse, any suitable location for the recesses 40 is contemplated withinthe scope of the disclosed embodiments. In at least one embodiment, therecesses 40 may have increased depths proximate to the edge 26 of thestructural layer 22 to facilitate retention of the cushion layer 24 onthe structural layer 22 during occupant ingress and egress, duringnormal riding conditions and during impact conditions.

The recesses 40 may have a circular shape, as illustrated. In anotherembodiment, the recesses 40 have an oval shape. Of course, any suitableshape for the recess 40 is contemplated within the scope of thedisclosed embodiments.

With reference now to FIG. 8 a, another cross-sectional view of anembodiment of the cushion composite 18 provided proximate the edge 26 ofthe structural layer 22 is illustrated covered by trim material 20. Theedge region 28 of the structural layer 22 has a recess 40 formedtherethrough, as discussed above. In the illustrated embodiment, ananti-slip ridge 44 is formed within the structural layer 22 to locatethe cushion layer 24 during assembly and retain the cushion layer 24after assembly and during use. In the depicted embodiment, the anti-slipridge 44 is provided adjacent the edge 26 of the structural layer 22. Asshown in FIG. 8 a, the cushion layer 24 has a protuberance 46 that aresized to be retained within the anti-slip ridges 44 of the structurallayer 22. Of course, any suitable amount of anti-slip ridges 44 andprotuberances 46 is contemplated within the scope of the disclosedembodiments. An interference fit may be employed between the anti-slipridges 44 and the protuberances 46 to retain the protuberances 46 withinthe anti-slip ridges 44. Of course, the protuberances 46 may be retainedwithin the anti-slip ridges 44 in any suitable manner.

The anti-slip ridges 44 may be provided adjacent the edge 26 of thestructural layer 22, as illustrated. As depicted in FIGS. 8 b and 9, theanti-slip ridges 44 be formed in the inner region 30 of the structurallayer 22 and may span from the edge region 28 across the inner region30. Of course, any suitable location for the anti-slip ridges iscontemplated within the scope of the disclosed embodiments.

Now with reference to FIG. 10, another embodiment of a portion of thevehicle seat assembly 10 of FIG. 1 is illustrated mounted to a floor pan48. The floor pan 48 is employed as a base for the vehicle seat assembly10 and mounts the vehicle seat assembly 10 to the vehicle. The floor pan48 may be made out of a sheet metal and formed as discussed furtherbelow.

With reference to FIGS. 11-14, the floor pan 48 has protrusions 50formed therein. The protrusions 50 are formed in the floor pan 48 atvarious locations so that the structural layer 22 can be located andretained on the protrusions 50. The structural layer 22 has receptors 52formed therein that are sized to receive the protrusions 50. Duringassembly, the receptors 52 locate the protrusions 50 to align thestructural layer 22 upon the floor pan. After assembly and during use,the interaction between the protrusions 50 and the receptors 52 improvesshock management, decreases squeaking caused by friction between thefloor pan 48 and the structural layer 22, improves adhesion andretention of the structural layer 22 upon the floor layer and minimizesslippage of the structural layer 22 relative to the floor pan 48.

As illustrated, the protrusions 50 have a saw tooth shape that nestswithin the receptors 52. The saw tooth protrusions 50 allow for contactbetween the protrusions 50 and the receptors 52 in order to retain thestructural layer 22 upon the floor pan 48 and also can reduce transferof movement and/or vibrations between the structural layer 22 and thefloor pan 48. An interference fit may be employed between theprotrusions 50 and the receptors 52 to retain the protrusions 50 withinthe receptors 52. Of course, the protrusions 50 may be retained withinthe receptors 52 in any suitable manner.

In FIG. 11, a first protrusion row 54 having one protrusion 50 is shownextending from the floor pan 48. The structural layer 22 has acorresponding first receptor row 56 having one receptor 52. As shown inFIG. 10, the cross-section depicted in FIG. 11 is provided towards themiddle of the structural member 22 and the floor pan 48. Although oneprotrusion 50 and one receptor 52 are illustrated, any suitable amountsof protrusions 50 and receptors 52 are contemplated to be formed in thefirst protrusion row 54 and the first receptor row 56.

In FIG. 12, a second protrusion row 58 having two protrusions 50 isshown extending from the floor pan 48. The structural layer 22 has acorresponding second receptor row 60 having two receptors 52 formedtherein that are sized to receive the protrusions 50. The secondprotrusion row 58 and the second receptor row 60 have a greater numberof respective protrusions 50 and receptors 52 than the first protrusionrow 54 and the first receptor row 56 of FIG. 11. As depicted in FIG. 10,the cross-section line 12-12 is provided proximate the cross-sectionline 11-11 and is provided closer to the edge 26 of the structural layer22. Proximate the edge 26 of the structural layer 22 more protrusions 50and receptors 52 may be provided to decrease slippage of the structurallayer 22 relative to the floor pan 48 since greater lateral forces maybe exerted on the structural layer 22 proximate the edge 26.

In FIG. 13, a third protrusion row 62 having three protrusions 50 isshown extending from the floor pan 48. The structural layer 22 has acorresponding third receptor row 64 having three receptors 52 formedtherein that are sized to receive the protrusions 50. The thirdprotrusion row 62 and the third receptor row 64 have a greater number ofrespective protrusions 50 and receptors 52 than the second protrusionrow 58 and the second receptor row 60 of FIG. 12. As depicted in FIG.10, the cross-section line 13-13 is provided proximate the cross-sectionline 12-12 and is provided closer to the edge 26 of the structural layer22. Proximate the edge 26 of the structural layer 22 more protrusions 50and receptors 52 may be provided to decrease slippage of the structurallayer 22 relative to the floor pan 48 since greater lateral forces maybe exerted on the structural layer 22 proximate the edge 26.

In FIG. 14, a fourth protrusion row 66 having four protrusions 50 isshown extending from the floor pan 48. The structural layer 22 has acorresponding fourth receptor row 68 having four receptors 52 formedtherein that are sized to receive the protrusions 50. The fourthprotrusion row 66 and the fourth receptor row 68 have a greater numberof respective protrusions 50 and receptors 52 than the third protrusionrow 62 and the third receptor row 64 of FIG. 13. As depicted in FIG. 10,the cross-section line 14-14 is provided proximate the cross-sectionline 13-13 and is provided closer to the edge 26 of the structural layer22. Proximate the edge 26 of the structural layer 22 more protrusions 50and receptors 52 may be provided to decrease slippage of the structurallayer 22 relative to the floor pan 48 since greater lateral forces maybe exerted on the structural layer 22 proximate the edge 26.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

1. A vehicle seat cushion composite comprising: a structural layeradapted to be mounted within a vehicle to provide support to anoccupant, the structural layer having at least two edge regions abuttingat least two edges of the structural layer and having an inner regionprovided between the at least two edge regions, the structural layerhaving at least one channel formed therein; and a cushion layer providedadjacent to the structural layer, the cushion layer having at least oneprojection sized to be received within the at least one channel of thestructural layer for minimizing lateral movement of the cushion layerrelative to the structural layer proximate the edge regions.
 2. Thevehicle seat cushion composite of claim 1 wherein the at least onechannel comprises a plurality of channels and the at least oneprojection comprises a plurality of projections; and wherein respectiveprojections of the plurality of projections are each receivable within arespective channel of the plurality of channels.
 3. The vehicle seatcushion composite of claim 1 wherein the inner region of the structurallayer further comprises a plurality of receptors provided therein; andwherein the cushion layer further comprises a plurality of protuberancessized to nest within the plurality of receptors of the structural layerto minimize lateral movement of the cushion layer relative to thestructural layer.
 4. The vehicle seat cushion composite of claim 1wherein the inner region of the structural layer further comprises aplurality of channels formed therein; and wherein the cushion layerfurther comprises a plurality of concave projections sized to bereceived within the plurality of concave channels of the inner region tominimize lateral movement of the cushion layer relative to thestructural layer, wherein each of the edge regions has a width of 10 to20 cm.
 5. The vehicle seat cushion composite of claim 2 wherein theplurality of channels have a depth of at least ten millimeters andextend concavely proximate the inner region toward at least one of theedges of the structural layer.
 6. The vehicle seat cushion composite ofclaim 2 wherein the structural layer has a density greater than adensity of the cushion layer and the channels have a depth of 5 to 25mm.
 7. The vehicle seat cushion composite of claim 2 wherein theplurality of projections are retained within the plurality of channelswith an interference fit and the channels have varying depths.
 8. Thevehicle seat cushion composite of claim 1 wherein the structural layeris made of expanded polyolefin.
 9. The vehicle seat cushion composite ofclaim 8 wherein the cushion layer is made of foam.
 10. A vehicle seatcushion composite comprising: a structural layer adapted to be mountedwithin a vehicle to provide support to an occupant, the structural layerhaving an edge region, with the edge region abutting an edge of thestructural layer, the structural layer having an inner region providedwithin the edge region; a cushion layer provided adjacent to thestructural layer, one of the edge region of the structural layer and thecushion layer having at least one recess formed therein, and the otherof the edge region of the structural layer and the cushion layer havingat least one projection sized to be received within the at least onerecess for minimizing lateral movement of the cushion layer relative tothe structural layer.
 11. The vehicle seat cushion composite of claim 10wherein one of the structural layer and the cushion layer furthercomprises anti-slip ridges and the other of the structural layer and thecushion layer comprises anti-slip protuberances sized to nest within theanti-slip ridges to minimize lateral movement of the cushion layerrelative to the structural layer.
 12. The vehicle seat cushion compositeof claim 10 wherein the at least one recess is further defined as atleast one aperture such that the at least one projection is receivedtherethrough.
 13. The vehicle seat cushion composite of claim 10 whereinthe structural layer is made of expanded polyolefin and the cushionlayer is made of foam.
 14. A vehicle seat assembly comprising: a floorpan adapted to be mounted within a vehicle; and a seat body mounted onthe floor pan to provide support to an occupant, one of the floor panand the seat body having a plurality of receptors formed therein, andthe other of the floor pan and the seat body having a plurality ofprotrusions formed therein and sized to be received within the pluralityof receptors.
 15. The vehicle seat assembly of claim 14 wherein theplurality of protrusions further comprises: a first protrusion rowhaving at least one protrusion; and a second protrusion row having aplurality of protrusions such that the second protrusion row has agreater number of protrusions than the first protrusion row; and whereinthe plurality of receptors further comprises: a first receptor rowhaving at least one receptor and sized to receive the first protrusionrow; and a second receptor row having a plurality of receptors and sizedto receive the second protrusion row.
 16. The vehicle seat assembly ofclaim 15 wherein the plurality of protrusions further comprises a thirdprotrusion row having a plurality of protrusions such that the thirdprotrusion row has a greater number of protrusions than the secondprotrusion row and the plurality of receptors further comprises a thirdreceptor row having a plurality of receptors and sized to receive thethird protrusion row.
 17. The vehicle seat assembly of claim 16 whereinthe plurality of protrusions further comprises a fourth protrusion rowhaving a plurality of protrusions such that the fourth protrusion rowhas a greater number of protrusions than the third protrusion row andthe plurality of receptors further comprises a fourth receptor rowhaving a plurality of receptors and sized to receive the fourthprotrusion row.
 18. The vehicle seat assembly of claim 14 wherein theplurality of protrusions have a saw tooth shape to nest within theplurality of receptors.
 19. The vehicle seat assembly of claim 14wherein the floor pan is made of metal and the seat body comprises astructural layer.
 20. The vehicle seat assembly of claim 19 wherein thestructural layer comprises expanded polyolefin.